Overview
The ZF 4657.024.166 4 WG 190 Powershift Transmission Assembly is a complete, factory-matched unit engineered for heavy-duty off-highway machinery. This assembly integrates the main gear cluster, clutch packs, and hydraulic control system into a single, ready-to-install package. As a core component of the WG 190 Series, it manages torque distribution across four forward and reverse speeds, enabling smooth directional shifts under load. The SKU 4657.024.166 replaces worn or failed assemblies in wheel loaders, dozers, and graders, restoring full driveline performance. It interfaces directly with the TRANSMISSION HOUSING to form the structural backbone of the gear train.
Symptoms of Failure
- Delayed or harsh engagement — When the 4657.024.166 assembly wears, internal clutch clearances increase, causing a noticeable lag or slam when shifting from neutral to forward or reverse. This is often the first sign of internal seal degradation.
- Oil leaks at the housing interface — Worn gaskets or cracked casting around the HOUS.FRONT SECT or HOUSING REAR PART allow transmission fluid to escape, leading to low pressure and eventual gear slipping.
- Gear slipping under load — As clutch plates wear, the assembly fails to hold torque, causing the machine to lose power on inclines or during heavy digging cycles. This symptom is frequently misdiagnosed as a pump issue.
- Unusual whining or grinding noises — Bearing fatigue inside the 4 WG 190 produces a high-pitched whine that increases with engine RPM, often accompanied by metallic debris in the oil pan.
Technical Specifications
| Parameter | Value |
|---|---|
| Part Number / SKU | 4657.024.166 |
| Assembly Type | Complete Powershift Transmission (4 WG 190) |
| Overall Length (approx.) | 720 mm |
| Overall Width (approx.) | 480 mm |
| Overall Height (approx.) | 510 mm |
| Dry Weight (approx.) | 185 kg |
| Housing Material | High-grade cast iron (GGG-40) |
| OEM Reference | ZF 4657.024.166 / WG 190 Series |
| Seal Type | Viton lip seals (all shift cylinders) |
| Torque Capacity | 1,900 Nm (max input) |
Compatibility
This complete unit is specifically designed for the ZF WG 190 Series, including models WG 190, WG 190 II, and WG 190 III. It is also mechanically compatible with the WG 180 and WG 200 series when used with the correct HOUSING REAR SECTION adapter. Common applications include ZF 4 WG 190 transmissions found in Caterpillar 950H, Volvo L120H, and Komatsu WA380 wheel loaders. Always verify the bellhousing pattern and output flange configuration before installation.
Related Components
| Part Number | Name | Function |
|---|---|---|
| 4657101079 | TRANSMISSION HOUSING | Main structural casing that encloses the gear train and oil sump. |
| 4657201166 | HOUS.FRONT SECT | Front section housing the input shaft and torque converter interface. |
| 4657201169 | HOUSING REAR PART | Rear casing that supports the output shaft and PTO drive. |
| 4657298104 | HOUSING REAR SECTION | Extended rear section for models requiring additional output support. |
| 0631306816 | CYLINDRICAL PIN | Alignment pin for precise housing-to-housing doweling. |
| 0636100801 | CAP SCREW | M12 hex-head bolt for securing housing flanges. |
| 4656301148 | FIXING PLATE | Locking plate for clutch piston retention. |
| 4657301032 | SCREEN SHEET | Fine mesh filter for the main pressure line. |
| 4657301033 | SCREEN SHEET | Coarse mesh filter for the return line. |
| 0636100803 | CAP SCREW | M14 hex-head bolt for heavy-duty flange connections. |
Frequently Asked Questions
Q: Can the ZF 4657.024.166 be rebuilt, or must it be replaced as a complete unit?
A: While individual clutch packs and seals are available, the 4657.024.166 is sold as a factory-balanced assembly. Rebuilding is possible but requires specialized tooling for end-play adjustment; most operators prefer a direct swap to minimize downtime.
Q: What is the typical service life of this 4 WG 190 assembly?
A: Under normal operating conditions with proper fluid maintenance (ZF TE-ML 03 spec oil changed every 500 hours), the assembly typically lasts 8,000 to 12,000 hours. Harsh applications like rock quarry loading may reduce this interval by 30%.
Q: Does this unit include the torque converter?
A: No. The 4657.024.166 is the transmission assembly only. The torque converter is a separate component (ZF part number 4657.024.167) and must be ordered independently if needed.
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Phone: +86 158 2286 3467 |
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